Dodge Caravan 2001-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Generation: Fourth Generation (RS) Codes Chassis Code: RS 👋 Introduction Market Position Segment: Minivan Target Audience: DIY Mechanics, Professional Technicians, Fleet Maintenance Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza Key Features Utility: Family hauling, cargo transport, versatile seating configurations Versatility: Available Stow 'n Go seating (later models) significantly enhanced cargo flexibility Value Proposition: Affordable family vehicle with a strong emphasis on practicality and passenger comfort 📋 Manual Details Coverage Areas Model Years: 2001, 2002, 2003, 2004, 2005, 2006, 2007 Regions Covered: North America (USA, Canada, Mexico) Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L V6 OHV, 3.8L V6 OHV, 4.0L V6 SOHC), Transmission (41TE/42LE Automatic) Chassis: Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc, ABS), Driveline (FWD) Electrical: Wiring Diagrams, Powertrain Control Modules (PCM), Body Control Modules (BCM), Lighting, Audio System, HVAC Controls, Power Accessories (Windows, Locks, Seats) Body: Body Repair, Exterior & Interior Trim, Doors, Glass, Seats, HVAC System Components, Safety Restraint System (SRS) Procedures Included Maintenance: Oil Change, Filter Replacements, Spark Plug Replacement, Fluid Checks & Changes, Belt Inspection & Replacement, Tire Rotation Diagnostics: Troubleshooting Flowcharts, Diagnostic Trouble Codes (DTCs), Component Testing, Sensor Readings, PCM Relearn Procedures Repair: Engine Overhaul, Transmission Repair/Overhaul, Brake System Repair, Suspension Component Replacement, Steering Rack Replacement, Electrical Component Diagnosis & Replacement, HVAC Component Repair Technical Specifications: Torque Specifications, Fluid Capacities, Electrical Schematics, Component Locations, Diagnostic Procedures Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable Text Content Printability: Printable Pages Print Quality Image Resolution: High-resolution for clear diagrams and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 3.3 Liters (3301 cc) Engine 1 Configuration: 3.3L V6 OHV (12 Valve) Engine 1 Power Hp: Approx. 180 hp @ 5000 RPM Engine 1 Torque Lb Ft: Approx. 205 lb-ft @ 3600 RPM Optional Engine Engine 2 Displacement: 3.8 Liters (3778 cc) Engine 2 Configuration: 3.8L V6 OHV (12 Valve) Engine 2 Power Hp: Approx. 200-215 hp @ 5000 RPM (depending on year/tune) Engine 2 Torque Lb Ft: Approx. 230-235 lb-ft @ 3600 RPM (depending on year/tune) Engine 3 Displacement: 4.0 Liters (3952 cc) Engine 3 Configuration: 4.0L V6 SOHC (24 Valve) Engine 3 Power Hp: Approx. 230 hp @ 5200 RPM Engine 3 Torque Lb Ft: Approx. 245 lb-ft @ 4000 RPM Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Cooling System Coolant Type: Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Extended Life (typically Mopar OAT or equivalent) Ignition System Spark Plugs: Platinum or Iridium type (e.g., Champion, NGK, Bosch - consult manual for exact OE spec and replacement intervals) Emission Controls System: On-Board Diagnostics (OBD-II), Catalytic Converter, EGR (Exhaust Gas Recirculation) 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (41TE / 42LE) Optional Optional Transmission: N/A (FWD models exclusively used the 4-speed automatic) Features Control Mode: Electronic Control with Torque Converter Lock-up Fluid Specifications Fluid Type: ATF+4 (Automatic Transmission Fluid, Type 9602 or equivalent) Fluid Capacities Fluid Capacity Quarts: Approx. 4.5-5.0 quarts (dry fill) / 3.5-4.0 quarts (drain and fill) Components Drive Type: Front-Wheel Drive (FWD) 📐 Dimensions Exterior Length In: Approx. 175-181 inches (depending on wheelbase configuration) Width In: Approx. 72 inches Height In: Approx. 68 inches Wheelbase In: Approx. 112-119 inches (depending on wheelbase) Interior Passenger Capacity: 7-8 Passengers (depending on seating configuration) Cargo Cargo Volume Cu Ft: Approx. 140-150 cu. ft. (with rear seats folded/removed) Weights Curb Weight Lbs: Approx. 3900-4400 lbs (depending on engine and trim) Gross Vehicle Weight Rating Gvwr Lbs: Approx. 5600-5900 lbs Towing Capacity Lbs: Approx. 2000-3800 lbs (depending on configuration and factory tow package) 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: Good (for applicable years/tests) NHTSA Frontal Passenger Rating: Good (for applicable years/tests) IIHS Frontal Offset Rating: Acceptable (for applicable years/tests) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) on some models/trims Passive Features Airbags Front: Standard Driver and Front Passenger Airbags Airbags Side: Optional Front Side-Impact Airbags Seatbelts: 3-Point Seatbelts with Pretensioners and Load Limiters (Front), 3-Point Seatbelts (Rear) Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) System on rear seats 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with CD player or cassette. Optional Infinity audio systems and rear-seat entertainment systems were available on higher trims. Navigation: Optional factory navigation system available on some higher-trim models from mid-2000s onwards. Driver Assistance Cruise Control: Standard cruise control Parking Assistance: Optional rear park assist sensors available on later models. Connectivity Auxiliary Input:...

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Tipo: Car

Fabricante:

Sku: 460416

Coleções: ALL Dodge

Disponibilidade: Em estoque

Tag: 2001 2002 2003 2004 2005 2006 2007 Car Caravan Cars Dodge Misc

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Generation:

Fourth Generation (RS)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

DIY Mechanics, Professional Technicians, Fleet Maintenance

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza

Key Features

Utility:

Family hauling, cargo transport, versatile seating configurations

Versatility:

Available Stow 'n Go seating (later models) significantly enhanced cargo flexibility

Value Proposition:

Affordable family vehicle with a strong emphasis on practicality and passenger comfort

📋 Manual Details

Coverage Areas

Model Years:

2001, 2002, 2003, 2004, 2005, 2006, 2007

Regions Covered:

North America (USA, Canada, Mexico)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (3.3L V6 OHV, 3.8L V6 OHV, 4.0L V6 SOHC), Transmission (41TE/42LE Automatic)

Chassis:

Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc, ABS), Driveline (FWD)

Electrical:

Wiring Diagrams, Powertrain Control Modules (PCM), Body Control Modules (BCM), Lighting, Audio System, HVAC Controls, Power Accessories (Windows, Locks, Seats)

Body:

Body Repair, Exterior & Interior Trim, Doors, Glass, Seats, HVAC System Components, Safety Restraint System (SRS)

Procedures Included

Maintenance:

Oil Change, Filter Replacements, Spark Plug Replacement, Fluid Checks & Changes, Belt Inspection & Replacement, Tire Rotation

Diagnostics:

Troubleshooting Flowcharts, Diagnostic Trouble Codes (DTCs), Component Testing, Sensor Readings, PCM Relearn Procedures

Repair:

Engine Overhaul, Transmission Repair/Overhaul, Brake System Repair, Suspension Component Replacement, Steering Rack Replacement, Electrical Component Diagnosis & Replacement, HVAC Component Repair

Technical Specifications:

Torque Specifications, Fluid Capacities, Electrical Schematics, Component Locations, Diagnostic Procedures

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced electrical diagnostics)

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable Text Content

Printability:

Printable Pages

Print Quality

Image Resolution:

High-resolution for clear diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

3.3 Liters (3301 cc)

Engine 1 Configuration:

3.3L V6 OHV (12 Valve)

Engine 1 Power Hp:

Approx. 180 hp @ 5000 RPM

Engine 1 Torque Lb Ft:

Approx. 205 lb-ft @ 3600 RPM

Optional Engine

Engine 2 Displacement:

3.8 Liters (3778 cc)

Engine 2 Configuration:

3.8L V6 OHV (12 Valve)

Engine 2 Power Hp:

Approx. 200-215 hp @ 5000 RPM (depending on year/tune)

Engine 2 Torque Lb Ft:

Approx. 230-235 lb-ft @ 3600 RPM (depending on year/tune)

Engine 3 Displacement:

4.0 Liters (3952 cc)

Engine 3 Configuration:

4.0L V6 SOHC (24 Valve)

Engine 3 Power Hp:

Approx. 230 hp @ 5200 RPM

Engine 3 Torque Lb Ft:

Approx. 245 lb-ft @ 4000 RPM

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Cooling System

Coolant Type:

Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Extended Life (typically Mopar OAT or equivalent)

Ignition System

Spark Plugs:

Platinum or Iridium type (e.g., Champion, NGK, Bosch - consult manual for exact OE spec and replacement intervals)

Emission Controls

System:

On-Board Diagnostics (OBD-II), Catalytic Converter, EGR (Exhaust Gas Recirculation)

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic (41TE / 42LE)

Optional

Optional Transmission:

N/A (FWD models exclusively used the 4-speed automatic)

Features

Control Mode:

Electronic Control with Torque Converter Lock-up

Fluid Specifications

Fluid Type:

ATF+4 (Automatic Transmission Fluid, Type 9602 or equivalent)

Fluid Capacities

Fluid Capacity Quarts:

Approx. 4.5-5.0 quarts (dry fill) / 3.5-4.0 quarts (drain and fill)

Components

Drive Type:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Length In:

Approx. 175-181 inches (depending on wheelbase configuration)

Width In:

Approx. 72 inches

Height In:

Approx. 68 inches

Wheelbase In:

Approx. 112-119 inches (depending on wheelbase)

Interior

Passenger Capacity:

7-8 Passengers (depending on seating configuration)

Cargo

Cargo Volume Cu Ft:

Approx. 140-150 cu. ft. (with rear seats folded/removed)

Weights

Curb Weight Lbs:

Approx. 3900-4400 lbs (depending on engine and trim)

Gross Vehicle Weight Rating Gvwr Lbs:

Approx. 5600-5900 lbs

Towing Capacity Lbs:

Approx. 2000-3800 lbs (depending on configuration and factory tow package)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Rating:

Good (for applicable years/tests)

NHTSA Frontal Passenger Rating:

Good (for applicable years/tests)

IIHS Frontal Offset Rating:

Acceptable (for applicable years/tests)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models/trims

Passive Features

Airbags Front:

Standard Driver and Front Passenger Airbags

Airbags Side:

Optional Front Side-Impact Airbags

Seatbelts:

3-Point Seatbelts with Pretensioners and Load Limiters (Front), 3-Point Seatbelts (Rear)

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) System on rear seats

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player or cassette. Optional Infinity audio systems and rear-seat entertainment systems were available on higher trims.

Navigation:

Optional factory navigation system available on some higher-trim models from mid-2000s onwards.

Driver Assistance

Cruise Control:

Standard cruise control

Parking Assistance:

Optional rear park assist sensors available on later models.

Connectivity

Auxiliary Input:

Generally not available on most models; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles:

Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult owner's manual/manual for specifics).

Transmission Fluid Change Interval Miles:

Every 30,000-100,000 miles, depending on usage and fluid type (ATF+4 often rated for longer intervals, but regular inspection and partial changes recommended).

Coolant Change Interval Miles:

Initial change at ~100,000 miles, then every ~50,000-75,000 miles for HOAT/OAT coolant.

Spark Plug Replacement Interval Miles:

Platinum plugs: ~100,000 miles; Iridium plugs: ~100,000 miles (consult manual for exact type and interval).

Fluid Specifications

Engine Oil Type And Viscosity:

SAE 5W-30 (preferred for most conditions, check manual for exceptions).

Engine Oil Capacity Quarts:

Approx. 4.5 quarts (3.3L) / 5.0 quarts (3.8L, 4.0L) with filter change.

Power Steering Fluid:

ATF+4 or specific Mopar power steering fluid.

Brake Fluid:

DOT 3 or DOT 4 (check cap/manual for precise specification).

Known Issues

Transmission Problems:

Potential issues include torque converter shudder, valve body issues, and solenoid failures. Early models of the 41TE were more prone to issues. Regular fluid changes are critical.

Engine Issues:

3.3L and 3.8L are generally robust but can suffer from intake manifold gasket leaks, oil cooler line leaks, and occasional head gasket issues. The 4.0L SOHC can experience timing chain wear and oil leaks.

Suspension Wear:

Common wear items include ball joints, tie rod ends, struts/shocks, and control arm bushings due to vehicle weight and family usage.

Electrical Issues:

Can include issues with power window motors, door lock actuators, HVAC blower motors, and intermittent issues with the BCM or PCM.

Exhaust System:

Corrosion of exhaust components, including catalytic converters and mufflers, is common in areas with road salt.

Body Rust:

Rust can form on rocker panels, wheel arches, and the rear quarter panels, especially in northern climates.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge has a long history of producing robust and practical vehicles, often targeting value-conscious buyers.

Model Evolution

Fourth Generation Introduction:

Introduced for the 1996 model year, the RS platform (which this manual covers) was a significant redesign, offering improved aerodynamics, safety, and interior space.

Mid-Cycle Refresh:

The 2001 model year marked a significant refresh for the fourth generation, with updated styling, interior amenities, and powertrain enhancements. This manual specifically covers this refreshed period.

Production

Manufacturing Locations:

Primarily Windsor, Ontario, Canada; Saltillo, Mexico

Platform Sharing:

Shared platform with Plymouth Grand Voyager and Chrysler Voyager/Town & Country (NS platform originally, RS platform for this era).

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The Dodge Caravan (and its Plymouth/Chrysler siblings) frequently appeared on Car and Driver's 10 Best lists in earlier generations, establishing its minivan credentials.

Consumer Reports:

Received varied ratings from Consumer Reports over the years, often praised for practicality but sometimes criticized for reliability in specific areas.

Certifications

Safety Certifications:

Met or exceeded all applicable Federal Motor Vehicle Safety Standards (FMVSS) for its model years.